Mattress Supporting System with Hinged Brackets for Headboard Support

ABSTRACT

A bed frame assembly has hinged brackets that can be used to attach a headboard to a bed frame. Each hinged bracket has two metal plates that each have metal tongues that are rolled into curved sections. A hinge is formed by sliding a pin through staggered curved sections on opposite metal plates. The metal plates pivotally rotate about the axis of the hinge such that the hinged bracket consumed less volume in a packing box when folded flat. Screws are inserted through slots in each metal plate to secure the hinged bracket to the bed frame. Tongues on a headboard are slid into slots in the metal plates of the hinged brackets in order to attach the headboard to the bed frame.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of, and claims priority under35 U.S.C. § 120 from, U.S. patent application Ser. No. 14/711,799entitled “Mattress Supporting System with Locking Mechanism for LegSupports,” filed on May 14, 2015. Application Ser. No. 14/711,799, inturn, is a continuation-in-part of, and claims priority under 35 U.S.C.§ 120 from, U.S. patent application Ser. No. 12/655,859 entitled“Mattress Supporting System with Headboard Attachment,” filed on Jan. 7,2010, now U.S. Pat. No. 9,107,509. Application Ser. No. 14/711,799 isalso a continuation-in-part of, and claims priority under 35 U.S.C. §119 from Chinese Patent Application No. 20150005133.8, filed on Jan. 6,2015, in China. Application Ser. No. 12/655,859, in turn, is acontinuation-in-part of, and claims priority under 35 U.S.C. § 120 from,U.S. patent application Ser. No. 12/378,496 entitled “MattressSupporting System,” filed on Feb. 17, 2009, now U.S. Pat. No. 7,721,366.Application Ser. No. 12/378,496, in turn, is a continuation-in-part of,and claims priority under 35 U.S.C. § 120 from, U.S. patent applicationSer. No. 12/287,440 entitled “Folding Bed Frame,” filed on Oct. 8, 2008,now U.S. Pat. No. 7,600,278. Application Ser. No. 12/287,440, in turn,is a continuation-in-part of, and claims the benefit under 35 U.S.C. §119 from, Chinese Patent Application No. 200720008515.1, filed on Oct.19, 2007, in China. The contents of each of the aforementioned patentdocuments are incorporated herein by reference.

TECHNICAL FIELD

The described embodiments relate to bedding products, and moreparticularly to a folding bed frame and a mattress supporting system.

BACKGROUND INFORMATION

Conventional folding bed frames are relatively heavy and awkward. FIG. 1(prior art) shows the structure of a conventional folding bed frameincluding a mattress frame 1 and support legs 2. Mattress frame 1 can befolded in half. The plurality of support legs 2 are pivotally connectedunder the mattress frame 1. In use, a mattress (not shown) is placed onthe mattress frame 1. This structure of the folding bed frame mustpossess a certain level of bearing strength because the mattress frame 1must support the mattress. In order to provide bearing strength,mattress frame 1 is made with relatively thick cross-bars and thinnerlongitudinal bars. The thick cross-bars have relatively large intervalsbetween them, whereas the thinner longitudinal bars are spaced atrelatively small intervals. The thick cross-bars and the thinnerlongitudinal bars are both welded to mattress frame 1. Although the bedframe of FIG. 1 provides stable support for a mattress, the bed frame isawkward and bulky. Because this type of bed frame is typically made ofmetal, the crossed design of the thick cross-bars and the longitudinalbars increases the weight of the bed frame even further. Especially inthe case of a double bed that supports a queen or king size mattress,the bed frame is even more awkward and difficult to carry and transport.

In addition, the bed frame of FIG. 1 is not adaptable to differentmattress sizes. Even a conventional bed frame that is sized for either asingle bed or a double bed does not accommodate the various dimensionsof the single and double mattresses, such as single, twin, full, double,queen, king and California king. A different bed frame size must bemanufactured to accommodate each different mattress dimension. Becausethe bed frame of FIG. 1 cannot be standardized to fit multiple mattressdimensions, the manufacturing cost of the various sizes of the bed frameis increased.

A bed frame is sought that is lighter and less awkward than theconventional bed frame and that can accommodate multiple mattressdimensions. In addition, a folding bed frame is sought that can replacea conventional box spring.

SUMMARY

A folding bed frame includes standardized right and left bed frameassemblies. The bed frame assemblies are connected by a plurality ofcentral connecting bars to form an adjustable bedboard frame that canaccommodate mattresses of differing widths. The small, standardized bedframe assemblies can be manufactured at less cost than can aconventional unitary bed frame. In addition, the folding bed frame iseasy to transport when disassembled into the separate frame assembliesthat are each less than half the width of a conventional bed frame for adouble bed. The bedboard frame formed by the standardized frameassemblies and the central connecting bars is lighter than theconventional unitary bed frame and is therefore less expensive totransport and easier to install.

Leg supports are pivotally connected to the bottom of the bedboard frameunder each bed frame assembly and support the bedboard frame andmattress. Each central connecting bar has U-shaped slots on its endsthat clip over the inner side edges of the right and left bed frameassemblies. Each frame assembly has a hinge at its middle axis at whicha lower half of the assembly folds over onto an upper half of theassembly to allow the frame assemblies to fit in a packing box. The legsupports fold in to fit in the packing box.

Edge attachments are attached by screws to the upper left corner of theleft bed frame assembly and to the upper right corner of right bed frameassembly. A headboard of the bed attaches to the edge attachments of thefolding bed frame. Tongues on the headboard slip into slots in the edgeattachments.

A method of packing the folding bed frame into a packing box involvesfolding lower halves of the bedboard frames of bed frame assemblies overonto upper halves of the bedboard frames. The leg supports that arepivotally connected to the bedboard frames are folded in. The foldedbedboard frames are then inserted into a packing box that is about halfas long as the unfolded bedboard frames. The packing box has a width oflittle more than the width of one bed frame assembly. The packing box isabout four times as thick as the folded-in leg supports plus four timesas thick as an unfolded bedboard frame. Central connecting bars areinserted into the packing box and fit between the folded-in legsupports.

In one embodiment, the folding bed frame includes no central connectingbars. The folding bed frame includes right and left bed frameassemblies. The right bed frame assembly has a left inner side edge thatfaces the left bed frame assembly, and the left bed frame assembly has aright inner side edge that faces the right bed frame assembly. The leftinner side edge is directly connected to the right inner side edge andforms a bedboard frame for a single bed.

An apparatus includes a packing box and a means for assembling a bedframe that fits mattresses of differing widths. The means is insertedinto the packing box. The bed frame is adaptable to fit a mattresshaving an area that is larger than four times the length times the widthof the packing box.

A folding bed frame comprises mutually connected left and right bedframe assemblies, one on each side. Each bed frame assembly includes abedboard frame and a plurality of leg supports that are pivotallyconnected under the bedboard frame. In one aspect, a bedboard frame fora single bed is provided in which no central connecting bars are used.In another aspect, a plurality of central connecting bars span betweenthe left and right bed frame assemblies. Central connecting bars withdifferent lengths are selected to accommodate mattresses of differentwidths. Thus, a bedboard frame for double beds with different widths canbe conveniently manufactured without the need to re-manufacture the bedframe assemblies. The specifications of the bed frame assemblies arestandardized, which greatly reduces the manufacturing cost of thefolding bed frame.

In another embodiment, an apparatus includes a bed frame assembly and anedge attachment. The bed frame assembly has a hinge at which a firstportion of the bed frame assembly is adapted to fold over onto a secondportion of the bed frame assembly. A leg support is pivotally connectedto the bed frame assembly. The edge attachment clips over a head sideedge and an outer side edge of the bed frame assembly and is adapted tohold a bed skirt taut around the bed frame assembly when the bed frameassembly is resting on the extended leg support.

The edge attachment holds the bed skirt such that more than half of theleg support is not visible behind the bed skirt when the bed frameassembly is resting on the extended leg support. The bed frame assemblyalso includes a second edge attachment that holds the bed skirt and thatclips over the middle of the outer side edge of the bed frame assembly.A third edge attachment is attached to the head side edge and the outerside edge of the bed frame assembly and both holds the bed skirt tautaround the bed frame assembly and holds a headboard.

The edge attachments at the corners of the bed frame assembly slant atan angle down and away from the bed frame assembly when no bed skirt isbeing held so that a bed skirt is held taut when the bed skirt isslipped on over the slanted edge attachments. A storage container with afloor height of at least twelve inches can slide past the bed skirtunder the bed when the taut bed skirt is stretched.

A method for setting up a mattress support system includes the steps of:(i) removing a folded bed frame assembly and an edge attachment from apacking box, (ii) unfolding a first portion of the bed frame assemblyfrom a second portion of the bed frame assembly that is pivotallyconnected to the first portion at a hinge, (iii) unfolding a leg supportthat is pivotally connected to the bed frame assembly, (iv) standing theunfolded bed frame on the unfolded leg support, (v) attaching the edgeattachment at a corner or the bed frame assembly, (vi) slipping a bedskirt down over the edge attachment such that the bed skirt is held tautaround the bed frame assembly when the bed frame assembly is standing onthe unfolded leg support, and (vii) placing a mattress on top of theassembled bed frame assembly. The method also includes the steps ofattaching a second edge attachment to the bed frame assembly at a secondcorner and attaching a headboard to the second edge attachment.

In yet another embodiment, an apparatus includes a bed frame assemblyand a means for holding a bed skirt taut around the bed frame assemblywhen the bed frame assembly is standing on leg supports. The means isalso for holding a headboard of the bed frame assembly. The bed frameassembly has a hinge at which a first portion of the bed frame assemblyfolds over onto a second portion of the bed frame assembly. The bedframe assembly has leg supports that are pivotally connected to the bedframe assembly.

In yet another embodiment, a mattress supporting system includes a bedframe, an edge attachment and a headboard attachment. The headboardattachment is adapted to hold a headboard. The bed frame assembly has aleg support that is pivotally connected to the bed frame assembly. Theedge attachment is attached to a head side edge and to an outer sideedge of the bed frame assembly. The edge attachment is adapted to hold abed skirt taut around the bed frame assembly when the bed frame assemblyis resting on the extended leg support. The headboard attachment isattached to the leg support and extends out from under the bed skirtlaterally past the head side edge. The headboard attachment has an anglebracket that rests on a cross bar of the leg support when the headboardattachment is attached to the leg support.

A method of supporting a headboard includes unfolding a first portion ofa bed frame assembly from a second portion of the bed frame assembly. Aleg support is pivotally connected to the first portion. The first andsecond portions are pivotally connected at a hinge. When the bed frameassembly is unfolded, the assembly has an outer side edge and a headside edge that meet at a corner.

The leg support is unfolded, and the unfolded bed frame is stood on theunfolded leg support. An edge attachment is attached at the corner wherethe outer side edge and the head side edge meet. A bed skirt is slippeddown over the edge attachment such that the bed skirt is held tautaround the bed frame assembly. A headboard attachment is attached to theleg support such that the headboard attachment extends out from underthe bed skirt laterally past the head side edge. A headboard is thenattached to the headboard attachment.

The folding mattress support system replaces a conventional bed framewith rails and the box spring. The mattress support system is lighter,easier to transport, and provides more storage space beneath themattress. The mattress support system includes bed frame assemblies,central connecting bars, edge attachments, headboard attachments and abed skirt. Leg supports fold out from the bed frame assemblies, whichthemselves unfold in the middle. Central connecting bars connect innerside edges of the bed frame assemblies. Plastic edge attachments areattached at outer corners of the bed frame assemblies and hold a bedskirt taut when the frame assemblies are standing on extended legsupports. A mattress is then placed on top of the assembled mattresssupport system. Optionally, metal edge attachments at the head cornershold both the bed skirt and a headboard. Alternatively, headboardattachments protrude from under the bed skirt and support a headboard.

In yet another embodiment, the mattress support system is a bed frameassembly with diagonal struts that lock leg supports into place usingnovel locking mechanisms. The bed frame assembly has a hinge at which afirst portion of the bed frame assembly is adapted to unfold from asecond portion of the bed frame assembly. The bed frame assembly has afirst cross bar, a second cross bar, longitudinal bars, leg supports,diagonal struts and the locking mechanisms. Opposite ends of the crossbars are attached to the longitudinal bars. A leg support is pivotallyattached to the first cross bar, and a slotted bracket with a roundedslot is attached to the second cross bar. Attached to a first end of adiagonal strut is a bolt with a conical washer on the bolt. The secondend of the diagonal strut is pivotally attached to the leg support, andthe first end of the diagonal strut is attached to the slotted bracketby inserting the bolt into the rounded slot and by pressing the conicalwasher down into the rounded slot using a wing nut. The rounded slot hasa round opening at the end of a channel whose width is slightly largerthan the diameter of the bolt. The diameter of the round opening islarger than the width of the channel and smaller than the largestdiameter of a coned portion of the conical washer.

In another embodiment, an apparatus includes a bed frame assembly andhinged brackets. Each hinged bracket attaches to the bed frame assemblyto support a headboard. Each hinged bracket includes a first planarmetal plate portion and a second metal plate portion that each have aset of rolled metal tongues. The rolled metal tongues are shaped to formcurved sections. The curved sections of the first and second planarmetal plate portions are joined with pins and nuts to form a first hingeand a second hinge. The first and second planar metal plate portionspivotally rotate about the axis of the first and second hinges such thatthe hinged bracket takes up less volume when placed in a packing box.The first and second planar metal plate portions each include slots intowhich the tongues on a headboard can be inserted. The hinged bracketsattach to the upper-left and upper-right sides of the bedboard frame byscrews that are inserted into slots in the first and second planar metalplate portions.

A method for assembling the mattress support system includes unfoldingthe bed frame assembly and the leg supports, and then locking each legsupport in place by inserting a bolt into a rounded slot and pressing aconical washer into a round opening of the rounded slot. A first portionof the bed frame assembly is unfolded from a second portion of the bedframe assembly. The first portion and the second portion are pivotallyconnected at a hinge. A leg support is pivotally connected to the firstportion. The leg support has two legs disposed in a plane, and the twolegs are connected by a support bar. After the leg support is unfoldedfrom the first portion, a diagonal strut that is pivotally attached tothe support bar is rotated out of the plane of the leg support. A boltis fixedly attached to an end of the diagonal strut opposite the supportbar. A conical washer passes over the bolt and is held on the bolt by awing nut. The bolt is inserted into a round opening of a rounded slot ina slotted bracket by rotating the diagonal strut. The slotted bracket isattached to a cross bar of the bed frame assembly. The wing nut istightened so as to press the conical washer down into the round opening,whose diameter is smaller than the maximum diameter of the coned portionof the conical washer. After the mattress support system is assembled, amattress is placed on top of the bed frame assembly.

Further details and embodiments are described in the detaileddescription below. This summary does not purport to define theinvention. The invention is defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate embodiments of the invention.

FIG. 1 (prior art) is a schematic view of a conventional folding bedframe.

FIG. 2 is a schematic view of a novel folding bed frame that includescentral connecting bars.

FIG. 3 is a more detailed view of one of the central connecting bars ofthe folding bed frame of FIG. 2.

FIG. 4 is a schematic view of an edge attachment of the bed frame ofFIG. 2 to which a headboard can be attached.

FIG. 5 is a perspective, cut-away view of a king size mattress placed onthe folding bed frame of FIG. 2.

FIG. 6 is a schematic view of another embodiment of the folding bedframe of FIG. 2.

FIG. 7 is a flowchart illustrating steps of a method of packing thefolding bed frame of FIG. 2 into a packing box.

FIG. 8 is a perspective view of another embodiment of folding bed framesthat form a mattress support system with edge attachments that hold abed skirt taut.

FIG. 9 shows an edge attachment of FIG. 8 in more detail.

FIG. 10 is a cut-away view of a bed skirt that has been slipped on overthe edge attachment of FIG. 9.

FIG. 11 is a perspective view of the mattress support system of FIG. 8after a bed skirt has been slipped down over edge attachments and isheld taut.

FIG. 12 is a rear view of the edge attachment of FIG. 9.

FIG. 13 illustrates a large storage container being slid past the bedskirt and inserted under the mattress support system of FIG. 8.

FIG. 14 is a perspective view illustrating how storage containers fitunderneath the mattress support system of FIG. 8.

FIG. 15 is a flowchart illustrating steps of a method of assembling themattress support system of FIG. 8.

FIG. 16 is a perspective view of a mattress on top of the assembledmattress support system of FIG. 8 after the method of FIG. 15 has beenperformed.

FIG. 17 is a perspective view of another embodiment in which solidplastic edge attachments cover the sides of the mattress support systemin place of the bed skirt.

FIG. 18 illustrates a mattress supporting system that includes both edgeattachments for holding a bed skirt as well as headboard attachments forattaching a headboard.

FIG. 19 is a more detailed view of a headboard attachment of FIG. 18.

FIG. 20 shows the headboard attachment of FIG. 19 from a differentangle.

FIG. 21 shows another embodiment of a headboard attachment attached to aleg and cross bar of a mattress supporting system.

FIG. 22 shows the headboard attachment of FIG. 21 attached to a mattresssupporting system over which a bed skirt has been drawn.

FIG. 23 shows another embodiment of the mattress supporting system thatincludes a locking mechanism for the leg supports.

FIG. 24 shows the upper portion of the bed frame assembly of FIG. 23 inmore detail from the underside.

FIG. 25 shows the locking mechanism of the bed frame assembly of FIG. 24in more detail.

FIG. 26 is a schematic diagram from above showing how a bolt on adiagonal strut passes through a channel and into a round opening of arounded slot in a slotted bracket.

FIG. 27 is a cross-sectional schematic diagram of a bolt centered in around opening of the rounded slot of FIG. 26 before a conical washer islowered into the round opening.

FIG. 28 is a perspective schematic view of the locking mechanism of FIG.27 after the conical washer has been tightened by the wing nut into theround opening of the rounded slot.

FIG. 29 is a perspective view of the locking mechanism of FIG. 27 inwhich the wing nut has not yet tightened the conical washer all the waydown into the round opening of the rounded slot.

FIG. 30 is a flowchart illustrating steps of a method of assembling themattress support system of FIG. 23.

FIG. 31 shows another embodiment of the mattress supporting system thatincludes hinged brackets to which a headboard can be attached.

FIG. 32 is a perspective view of the hinged bracket (left side) of FIG.31 after being attached to the upper-left portion of the mattresssupporting system.

FIG. 33 is a perspective schematic view of the hinged bracket of FIG. 32in which the first planar metal portion is perpendicular to the secondplanar metal portion.

FIG. 34 is a perspective schematic view of the hinged bracket of FIG. 33in which the first planar metal portion is in the same plane as thesecond planar metal portion.

FIG. 35 shows how the first and second planar metal plate portions ofthe hinged bracket are joined and folded around a hinge axis.

DETAILED DESCRIPTION

A less costly folding bed frame is disclosed that can accommodatemattresses of various dimensions. A standardized bed frame is providedthat can be conveniently adjusted to various mattress widths. Thefolding bed frame includes a left bed frame assembly and a right bedframe assembly connected by a plurality of central connecting bars. Theassembled bed frame forms a bedboard frame and a plurality of legs thatare pivotally connected under the bedboard frame. The central connectingbars form part of the bedboard frame and connect the left bed frameassembly to the right bed frame assembly. Each end of each centralconnecting bar has a U-shaped slot opening downward. A U-shaped slot isclipped down over the inner side edge of a bed frame assembly. In oneembodiment, the left and right bed frame assemblies are connected toeach other via the central connecting bars through riveting or screwing.

In the description and claims, terms such as “upper”, “lower”, “top”,“bottom”, “up”, and “down” are used to describe relative directions andorientations between different parts of the mattress support system, andit is to be understood that the overall structure being described canactually be oriented in any way in three-dimensional space. For example,when a first object is described as being pressed down into a secondobject, it is to be understood that the first object may in fact bepressed up into the second object. When a first object is referred to asbeing disposed “over” or “on” a second object, it is to be understoodthat the first object can be directly on the second object, or anintervening object may be present between the first and second objects.

The combined width of the pair of bed frame assemblies is narrower thanthe width of a traditional folding bed frame for a double bed. Byconnecting the left and right bed frame assemblies directly to eachother through bolts, riveting or screwing without using the centralconnecting bars, a frame for a single bed is provided. A frame for adouble bed is provided by spanning the plurality of central connectingbars between the left and right bed frame assemblies. Thus, thestandardized left and right bed frame assemblies are adaptable to formframes for mattresses of various dimensions. In addition, thestandardized left and right bed frame assemblies reduce the cost ofmanufacturing bed frames that accommodate different sized mattresses.

Because the central connecting bars are independent of the standardizedleft and right bed frame assemblies, the lengths of the bars can beeasily varied. Bed frames that can accommodate different widths ofmattresses can be manufactured simply by producing central connectingbars with different lengths. Central connecting bars having a specifiedlength can be selected to match the width requirement of each bedwithout the need to re-manufacture a bedboard frame. Thus, the novel bedframe has a greatly reduced manufacturing cost.

Especially when configured as a frame for a double bed, the novelfolding bed frame is much lighter than conventional folding bed frameswith cross and longitudinal bars. The weight of the central connectingbars is less than that of the welded cross and longitudinal bars.

The novel folding bed frame is also easier to transport than aconventional folding bed frame.

Conventional frames have a single mattress frame whose size hampers theease of transport. The novel bed frame is divided into two bed frameassemblies connected by central connecting bars. The novel bed frame canbe disassembled into the two separate bed frame assemblies that areeasier to carry and transport.

FIG. 2 shows a novel folding bed frame 10 that can accommodatemattresses of differing dimensions. Bed frame 10 includes a left bedframe assembly 11, a right bed frame assembly 12, and a plurality ofcentral connecting bars 13. Each of frame assemblies 11 and 12 resemblesa very narrow folding bed frame. Each of frame assemblies 11 and 12includes a bedboard frame 14 and a plurality of leg supports 15pivotally connected under the bedboard frame 11. The bed frameassemblies 11 and 12 stand upon the leg supports 15 when the legsupports are folded out and locked. A bedboard frame is formed bylongitudinal bars 16 welded to cross bars 17. In one embodiment, thelongitudinal bars 16 are metal rods. Each leg support 15 includes twolegs. Three exemplary leg supports 15 are labeled in FIG. 2. Left bedframe assembly 11 differs from a conventional folding bed frame in thatassembly 11 is narrower, normally less than half the width of a framefor a double bed.

FIG. 3 shows an exemplary central connecting bar 13 in more detail. Eachcentral connecting bar is disposed between left bed frame assembly 11and right bed frame assembly 12. Both ends of each central connectingbar 13 have a U-shaped slot 18 opening downward. The U-shaped slot 18 isclipped down over an inner side edge 19 of one of frame assemblies 11 or12.

In another embodiment, the connection between the end of a centralconnecting bar 13 and an inner side edge 19 is made by inserting anarrow tip of the connecting bar through a hole in the side edge 19.Alternatively, the end of a central connecting bar 13 is bolted to theside edge 19. Other connection means can also be used to connect thecentral connecting bars to the inner side edges.

Folding bed frame 10 is shipped from the manufacturer to retail storesin a disassembled condition. Typically, a customer also purchasesfolding bed frame 10 in a disassembled condition and assembles the bedframe at home in the bedroom where the bed frame will be used. All ofthe disassembled pieces of folding bed frame 10 fit in a packing boxhaving a length that is about half the length of each bed frameassembly. In the packing box, each bed frame assembly is folded at itsmiddle axis 20, which is hinged. For example, the lower half of each bedframe assembly is folded over onto the upper half of the frame assemblyin order to fit in the packing box. The packing box has a width oflittle more than the width of one bed frame assembly. The thickness ofthe box is about four times the thickness of the bedboard frame plusfour times the thickness occupied by a folded leg support 15. Thecentral connecting bars fit in the packing box between the folded-in legsupports. Thus, the area defined by the length and width of the packingbox is less than a quarter of the area of the mattress that fits on thebedboard frame formed by the bed frame assemblies and the centralconnecting bars.

To assemble bed frame 10, bed frame assemblies 11 and 12 are firstdeployed. The bedboard frame 14 of each bed frame assembly is unfolded,and the three leg supports 15 of each frame assembly are folded out andlocked. Right bed frame assembly 12 is placed to the right of left bedframe assembly 11. Next, the plurality of central connecting bars 13 arefixedly clipped onto the inner edges 19 of left and right bed frameassemblies 11 and 12 such that the bars transversely span between theleft and right bed frame assemblies 11 and 12. The U-shaped slots 18 areclipped down over the metal bars that form the inner edges 19. Next,edge attachments 21 (not shown in FIG. 2) are attached by screws to theupper left corner of left bed frame assembly 11 and to the upper rightcorner of right bed frame assembly 12.

FIG. 4 shows the edge attachment 21 attached to the right head corner ofright bed frame assembly 12. In this embodiment, edge attachment 21clips over a head side edge as well as over an outer side edge of rightbed frame assembly 12. Then edge attachment 21 is screwed in and hangsdown from the side edge of right bed frame assembly 12. A headboard isattached to the edge attachments. Tongues on the headboard slip intoslots 22 in edge attachment 21.

FIG. 5 shows a king size mattress 23 placed on 14 bedboard frame 14 offolding bed frame 10. A headboard 24 is attached to edge attachments 21.FIG. 5 illustrates that the area of bedboard frame 14 formed by thelongitudinal bars 16 and cross bars 17 is limited to the sides where thebed frame assemblies are located. The central area of bedboard frame 14is formed by the central connecting bars 13. Because the weight of thecentral connecting bars 13 is less than that of the longitudinal bars 16and cross bars 17, folding bed frame 10 is lighter and less awkward.Folding bed frame 10 is also less awkward than conventional bed framesbecause the size of the disassembled, folded bed frame inside thepacking box is smaller and can be more easily fit inside the trunk of acar or through a doorway.

Left and right bed frame assemblies 11 and 12 provide support on theside edges of mattresses of every width. Edge support is beneficial, asconsumers tend to sit on the side of a mattress before getting in andout of bed. In one embodiment, some unsupported length remains at thefoot of the mattress because the length of left and right bed frameassemblies 11 and 12 fits the length of a single mattress, and aheadboard is attached to the head of the bed frame assemblies. Inanother embodiment, a central connecting bar connects the foot sideedges of left and right bed frame assemblies 11 and 12 and providessupport for mattress 23 at the foot of the bed.

In addition, the manufacturing cost of folding bed frame 10 is reducedbecause bed frame assemblies 11 and 12 are standardized, and the lengthof the central connecting bars 13 can be adjusted. In one embodiment,central connecting bars 13 having a length that is appropriate for thewidth of a certain mattress are included in the packing box. Forexample, shorter connecting bars are included in the packing box of abed frame for a queen size mattress than are included in the box for aking size mattress. In another embodiment, the central connecting barsare conveniently adjustable by allowing one side of each connecting barto telescope into the other side of the connecting bar. A screw from theouter bar then tightens into the inner bar to fix the length of theconnecting bar. Alternatively, a connecting bar is made adjustable bysliding a smaller U-shaped bar inside a larger, outer U-shaped bar.

FIG. 6 shows another embodiment of folding bed frame 10 in which nocentral connecting bars are used. Left and right bed frame assemblies 11and 12 are placed directly adjacent to each other. The inner side edges19 of the bed frame assemblies 11 and 12 are attached to each other bybolts 25 and nuts. Alternatively, the bed frame assemblies 11 and 12 canbe connected by screws or rivets. The bed frame of FIG. 6 has a widththat is appropriate for a narrow mattress, such as an extra-long collegetwin mattress that measures 38 inches by 84 inches. Thus, the samestandardized bed frame assemblies 11 and 12 form a bedboard frame 14that supports mattresses of different dimensions. Not only is themanufacturing cost reduced, but the disassembled folding bed frame canbe more conveniently packaged and transported.

FIG. 7 is a flowchart illustrating steps 26-31 of a method of packingfolding bed frame 10 into a packing box that is conveniently sized fortransporting. In a first step 26, a lower half of the bedboard frame 14of right bed frame assembly 12 is folded over onto an upper half of thebedboard frame. Bedboard frame 14 is folded over at a hinge at middleaxis 20.

In step 27, a first leg support 15 that is pivotally connected to thebedboard frame 14 of right bed frame assembly 12 is folded in. In step28, a lower half of the bedboard frame 14 of left bed frame assembly 11is folded over onto an upper half of the bedboard frame. In step 29, asecond leg support 15 that is pivotally connected to the bedboard frame14 of left bed frame assembly 11 is folded in. In step 30, the foldedbedboard frame of right bed frame assembly 12 and the folded bedboardframe of left bed frame assembly 11 are inserted into a packing box. Thepacking box is about half as long as the unfolded bedboard frame ofright bed frame assembly 12. The packing box has a width of little morethan the width of right bed frame assembly 12. The packing box is aboutfour times as thick as the folded first leg support plus four times asthick as the unfolded bedboard frame of right bed frame assembly 12. Instep 31, a central connecting bar 13 is inserted into the packing box.The central connecting bar 13 is adapted to connect the bedboard frameof left bed frame assembly 11 to the bedboard frame of right bed frameassembly 12.

FIG. 8 illustrates another embodiment of a folding bed frame thatincludes edge attachments for holding a bed skirt. The folding bed frameof FIG. 8 provides a mattress supporting system 32 that performs thefunctions of both a conventional box spring and a conventional metal bedframe with wood rails. Thus, mattress supporting system 32 can replaceconventional bed frames and box springs. Mattress supporting system 32includes left bed frame assembly 11, right bed frame assembly 12, andcentral connecting bars 13. Each of the bed frame assemblies 11 and 12includes a bedboard frame 14. The bed frame assemblies 11 and 12 standupon leg supports 15 when the leg supports are folded out and locked.Each bed frame assembly has a hinge at its middle axis 20 at which alower portion of the assembly unfolds from an upper portion.

Mattress supporting system 32 includes an edge attachment 33 attached tothe right foot corner 34 (the lower right corner) of right bed frameassembly. (For simplicity, the remaining edge attachments are not shownin FIG. 8, but are illustrated in subsequent figures.) Edge attachment33 clips over a foot side edge 35 and an outer side edge 36 of right bedframe assembly 12. Edge attachment 33 is adapted to hold a bed skirttaut around both bed frame assemblies of mattress supporting system 32when the bed frame assemblies are resting on the extended leg supports15.

In one embodiment of mattress supporting system 32, edge attachment 33and the other edge attachments (not shown) slant at an angle 37 down andaway from the bed frame assemblies when no bed skirt is being held suchthat a bed skirt that is slipped on over the slanted edge attachments isheld taut. Edge attachment 33 slants down at an angle 37 that is aboutfive to ten degrees from vertical. The bottom edge of the bed skirt isheld taut as the bed skirt pulls the bottoms of the edge attachmentsinward. Thus, the long side of edge attachment 33 is oriented verticallywhen the bed skirt is slipped over mattress supporting system 32.

FIG. 9 shows edge attachment 33 in more detail. In one embodiment, edgeattachment 33 is made of hard molded plastic. Edge attachments at thefoot of a bed are preferably made of plastic instead of metal to avoidinjury to the shins, feet and children as consumers walk around the footof mattress support system 32. Plastic edge attachments are also lessexpensive to manufacture than metal edge attachments. In addition,plastic edge attachments are lighter weight than metal edge attachmentsand are therefore less expensive to transport. Where stronger edgeattachments are required to hold both a bed skirt and a headboard, metalis used. Clips 38 on edge attachment 33 clip down over foot side edge 35and outer side edge 36 such that no screws, bolts or nuts are requiredto attach edge attachment 33 to the side edges.

FIG. 10 is a cut-away view of a bed skirt 39 that has been slipped onover slanted edge attachment 33. Bed skirt 39 has a skirt portion 40 andcenter fabric 41. Skirt portion 40 has an upper edge 42 and a lower edge43. While bed skirt 39 is slipped over the slanted edge attachments onthe four corners of mattress support system 32, the edge attachmentshold lower edge 43 of skirt portion 40 taut. Skirt portion 40 gives theappearance of a covering of a solid box spring. In one embodiment,center fabric 41 is made of a non-skid fabric such that a mattressplaced on mattress support system 32 does not slip.

FIG. 11 shows bed skirt 39 after being slipped down over edge attachment33 and the other edge attachments such that bed skirt 39 is held tautaround bed frame assemblies 11 and 12 when the bed frame assemblies arestanding on the unfolded leg supports 15. The edge attachments hold bedskirt 39 such that more than half of each leg support 15 is not visiblebehind bed skirt 39 when the bed frame assemblies are resting on theextended leg supports 15. Thus, mattress support system 32 appears to bea solid box spring sitting on short legs.

Although mattress support system 32 has an appearance similar to aconventional box spring, mattress support system 32 has severaladvantages over a conventional box spring that is supported by the metalrails of a conventional bed frame. First, mattress support system 32 iseasier to move than a conventional box spring. Whereas a conventionalbox spring is constructed with a unitary wood frame that cannot be bentor disassembled into pieces, mattress support system 32 can be deliveredin a relatively small packing box. Consequently, mattress support system32 can be transported in an elevator and moved around the bend in astaircase, whereas a queen or king size box spring may be too large orawkward. Mattress support system 32 fits in a packing box that is abouthalf as long as the unfolded bed frame assemblies and about as wide asthe width of one bed frame assembly.

Second, mattress support system 32 is lighter than a conventional bedframe and box spring, and thus is both less expensive and easier totransport. The wood frame of a conventional box spring has solid sides,which weigh more than the edge attachments of mattress support system 32over which the fabric of the bed skirt is stretched. Wood beams of aconventional box spring form both a top surface and a bottom surface,whereas the bottom of mattress support system 32 remains open. The legsupports of mattress support system 32 are lighter than a conventionalmetal bed frame with wooden rails upon which the conventional box springsits.

Third, mattress support system 32 is quieter than a conventional boxspring sitting on wooden rails of a bed frame. As a person moves on amattress, the joints in the wood of the box spring squeak. In addition,movement of the box spring over the wooden rails also makes noise. Themetal construction of mattress support system 32 is less likely to makenoise as a person moves on a mattress supported by the support system.

Fourth, mattress support system 32 provides a significant amount ofstorage space beneath the supported mattress. Because the wood frame ofa conventional box spring has solid sides and beams forming top andbottom surfaces, the volume inside a conventional box spring cannot beaccessed for storage. On the other hand, mattress support system 32 isopen at the bottom and permits that space between the leg supports 15 tobe used for storage.

FIG. 12 is a rear view of edge attachment 33 of FIG. 9. In the view ofFIG. 12, foot side edge 35 and outer side edge 36 have been cut away.FIG. 12 illustrates how a clip 38 clips down over and locks to outerside edge 36. Clip 38 holds edge attachment 33 firmly to the side edgeswithout using separate attachment pieces, such as screws, bolts or nuts.

FIG. 13 illustrates the significant storage area available beneath amattress supported by mattress support system 32. A large storagecontainer 44 can be slid past bed skirt 39 and inserted under mattresssupport system 32. Storage container 44 has a floor height of more thantwelve inches and would not fit under the rail of a conventional bedframe that stands only a few inches off the floor. A bed frame assemblyand an edge attachment 45 are adapted to allow storage container 44 toslide under the bed frame assembly when the taut bed skirt 39 isstretched at the middle of a side between edge attachments. In FIG. 13,skirt portion 40 of bed skirt 39 has been detached from left foot edgeattachment 45 to allow storage container 44 to be slid under mattresssupport system 32 past the skirt portion 40. In the embodiment of FIG.13, storage container 44 has a floor height of fourteen inches andslides below outer side edge 46.

FIG. 14 is a picture of mattress support system 32 illustrating howtwelve storage containers fit underneath bed frame assemblies 11 and 12and central connecting bars 13. For purposes of illustration, mattresssupport system 32 is shown in FIG. 14 without bed skirt 39. In additionto large storage container 44, which fits under left bed frame assembly11, there is an even bigger storage container 47 that fits under rightbed frame assembly 12 and central connecting bars 13. A smaller storagecontainer 48 slides under the side edges and under the diagonal supportbars 49 near the foot of the mattress support system 32.

In the embodiment of FIG. 14, mattress support system 32 has six edgeattachments: four at the corners and two at the middle of the sides. Inaddition to left foot edge attachment 45 and edge attachment 33 at thebottom right corner of mattress support system 32, FIG. 14 also shows aside edge attachment 50. Side edge attachment 50 stabilizes skirtportion 40 of bed skirt 39 at the middle of outer side edge 46 whileskirt portion 40 is being held taut by left foot edge attachment 45 anda left head edge attachment 51. In one embodiment, the bottom of sideedge attachment 50 holds lower edge 43 of skirt portion 40 down suchthat lower edge 43 forms a straight line from the bottom of left footedge attachment 45 to the bottom of left head edge attachment 51.

FIG. 15 is a flowchart illustrating steps 54-61 of a method of settingup mattress support system 32. In a first step 54, the contents areremoved from a packing box containing mattress support system 32. In theembodiment of FIG. 8, the packing box includes left bed frame assembly11, right bed frame assembly 12, seven central connecting bars 13, sixedge attachments 33, 45, 50-53 and bed skirt 39. Leg supports 15 arepart of bed frame assemblies 11 and 12. Thus, right bed frame assembly12 and edge attachment 33 are removed from the packing box.

In a step 55, the upper portion of each bed frame assembly is unfoldedfrom the lower portion at hinges located along middle axis 20. In thefolded condition in the packing box, the leg supports are folded intothe outer sides of each folded bed frame assembly. In step 55, the upperportion of right bed frame assembly 12 is unfolded from the lowerportion of bed frame assembly 12.

In a step 56, the leg supports 15 are unfolded. For example, a legsupport 62 that is pivotally connected to the upper portion of right bedframe assembly 12 is unfolded and locked into place.

In a step 57, the unfolded bed frame assemblies 11 and 12 are stood onthe unfolded leg supports 15. For example, the unfolded right bed frameassembly 12 is stood on unfolded leg supports 15, including unfolded andlocked leg support 62.

In a step 58, central connecting bars 13 are fixedly clipped onto theinner side edges of bed frame assemblies 11 and 12 such that the barstransversely span between the bed frame assemblies.

In a step 59, the edge attachments are attached to the outer corners andto the middle of the outer sides of bed frame assemblies 11 and 12. Forexample, edge attachment 33 is clipped down over the side edges at theright foot corner of mattress support system 32. Edge attachment 50 isclipped down over outer side edge 46 halfway between left foot edgeattachment 45 and left head edge attachment 51.

In a step 60, a bed skirt is slipped down over bed frame assemblies 11and 12 and over the edge attachments. The four edge attachments 33, 45,51, 52 at the corners of mattress support system 32 hold the bed skirttaut around the bed frame assemblies when the bed frame assemblies arestanding on the unfolded leg supports. For example, bed skirt 39 isslipped down over edge attachment 33 such that skirt portion 40 of bedskirt 39 is held taut around right bed frame assembly 12. When skirtportion 40 is pulled down over the edge attachments, center fabric 41 isalso pulled taut over the bedboard frames of bed frame assemblies 11 and12.

In a step 61, a mattress 63 is placed on center fabric 41 over theassembled mattress support system 32.

FIG. 16 shows the assembled mattress support system 32 after the methodof FIG. 15 has been performed. Mattress support system 32 has been setup with mattress 63 resting on top of center fabric 41.

In another embodiment, another type of edge attachment is attached tothe left head corner and to the right head corner of mattress supportsystem 32. In this embodiment, the edge attachments on the head cornersof mattress support system 32 are made of metal and resemble edgeattachment 21 of FIG. 4. The metal edge attachments either screw into orare clipped down over the side edges. Then bed skirt 39 is slipped downover the two plastic edge attachments at the foot corners and over thetwo metal edge attachments at the head corners of mattress supportsystem 32. Slits are made in the head side of skirt portion 40 to allowtongues on a headboard to slip into slots in the metal edge attachments.Thus, the metal edge attachments are used both to hold skirt portion 40taut around mattress support system 32, as well as to hold a headboard.As shown in FIG. 4, the metal edge attachment is adapted to hold aheadboard that attaches to the edge attachment only at locations belowthe head side edge of the bed frame assembly.

FIG. 17 shows yet another embodiment in which the edge attachments coverthe sides of mattress support system 32 in place of bed skirt 39. Theembodiment of FIG. 17 has solid plastic edge attachments 64 that snapdown with clips 65 over the side edges. Edge attachments 64 do notattach to the side edges at the corners, as do edge attachments 33, 45,51, 52, but rather attach along a large section of each side edge andmeet at the corners. In the embodiment of FIG. 17, there are two edgeattachments per side edge. The hard plastic of edge attachments 64 maybe made in different colors so as to provide beds in a variety ofcolors. When the sides of mattress support system 32 are covered by edgeattachments 33, 45, 51, 52, mattress support system 32 has theappearance of a platform bed.

FIG. 18 illustrates another embodiment of a mattress supporting system66 that includes both edge attachments for holding a bed skirt andseparate headboard attachments for attaching a headboard. Mattresssupporting system 66 includes six solid plastic edge attachments thatclip over the side edges, including left foot edge attachment 45, rightfeet edge attachment 33, left head edge attachment 51, right head edgeattachment 52, left side edge attachment 50 and right side edgeattachment 53. The plastic edge attachments 51-52 are not strong enoughto hold the weight of most headboards, so dual purpose metal edgeattachment of the type shown in FIG. 4 would be required both to hold abed skirt taut and to support a headboard. A headboard is attached todual purpose edge attachment 21 of FIG. 4 by slipping tongues on theheadboard into the slots 22 in edge attachment 21. Alternatively, boltson the headboard pass through the slots 22 and are fastened by nuts orwing nuts on the opposite side of edge attachment 21.

Where edge attachment 21 holds a bed skirt, however, attaching aheadboard onto edge attachment 21 requires slitting the bed skirt andpassing the tongues or bolts through the slits. Cutting or puncturingthe bed skirt may be considered undesirable and inconvenient. Moreover,the headboard must be removed in order to remove and replace the bedskirt. Mattress supporting system 66 includes a metal headboardattachment 67 that is separate from the plastic edge attachments 33, 45and 50-53 that hold the bed skirt. Headboard attachment 67 permits a bedskirt to be replaced without removing the headboard. In addition, thebed skirt need not be punctured or slit in order to allow bolts ortongues to pass from the headboard through the bed skirt to the edgeattachments.

Mattress supporting system 66 includes left bed frame assembly 11, rightbed frame assembly 12, and central connecting bars 13. The bed frameassemblies 11 and 12 stand upon leg supports 15 when the leg supportsare folded out and locked. Each leg support 15 includes two legs and across bar. For example, the upper left leg support 15 includes an outerleg 68 and a cross bar 69. Headboard attachment 67 attaches to leg 68and extends under the bed skirt laterally past head side edge 70.Mattress supporting system 66 also includes a second metal headboardattachment (not shown in FIG. 18) that is a mirror image of headboardattachment 67 and that attaches to the outer leg of the upper right legsupport. The headboard attaches to headboard attachment 67 only atlocations below head side edge 70 of left bed frame assembly 11. Theheadboard also attaches to the second headboard attachment at locationsbelow the head side edge of right bed frame assembly 12.

FIG. 19 shows headboard attachment 67 of FIG. 18 in more detail.Headboard attachment 67 has a main face 71 with slots 72 and a sidesurface 73. Side surface 73 prevents a person from cutting her shin onthe edge of main face 71 while walking around the upper left corner ofmattress supporting system 66 when a headboard is not attached toheadboard attachment 67. Tongues on a headboard slip into the slots 72in headboard attachment 67. Alternatively, bolts attached to theheadboard pass through the slots 72 and are tightened by nuts or wingnuts. Headboard attachment 67 also includes a separate fastening portion74 and an angle bracket 75 that protrudes from a flange 76. Fasteningportion 74 is used to clamp headboard attachment 67 to leg 68 bytightening wing nuts 77. When headboard attachment 67 is tightenedaround leg 68, angle bracket 75 rests on cross bar 69 of the leg supportand prevents a heavy headboard from causing headboard attachment 67 toslip down leg 68.

FIG. 20 is a view of headboard attachment 67 from a different angle.FIG. 20 shows fastening portion 74 loosened from the main body ofheadboard attachment 67. Leg 68 is clamped between flange 76 andfastening portion 74 using bolts and wing nuts.

FIG. 21 shows another embodiment of headboard attachment 67 attached toleg 68 and cross bar 69. The embodiment of FIG. 21 does not include aside surface 73. The view of FIG. 21 is shown without left head edgeattachment 51.

FIG. 22 shows the embodiment of FIG. 21 attached to a mattresssupporting system over which a bed skirt 78 has been drawn. Bed skirt 78has skirt portion 40 and center fabric 41. FIG. 22 shows upper edge 42and lower edge 43 of skirt portion 40. Slanted edge attachment 51 holdslower edge 43 of skirt portion 40 taut. Skirt portion 40 gives theappearance of a covering of a solid box spring. FIG. 22 also shows adashed outline of a headboard 79 that is attached to headboardattachment 67 and to the second headboard attachment located at theright head corner of the mattress supporting system.

FIG. 23 illustrates one of the bed frame assemblies of anotherembodiment of the mattress supporting system 66 that includes lockingmechanisms for the upper and lower leg supports. In the embodiment ofFIG. 18, a separate headboard attachment 67 is attached to upper legsupport 15 and must support the heavy headboard 79. Thus, the legsupport 15 must support the combined weight of the mattress, theoccupant of the bed and the headboard. The bed frame assembly 80 of FIG.23 includes sturdy diagonal struts 81-84 with locking mechanisms 85-88,respectively, that prevent the upper and lower leg supports 89-90 fromangling away from vertical under the combined weight.

Bed frame assembly 80 includes a plurality of leg supports 89-91pivotally connected to a bedboard frame 92. Assembly 80 stands upon theleg supports 89-91 when the leg supports are folded out and locked.Bedboard frame 92 is formed by longitudinal bars 93-96 welded to crossbars 97-104. Each leg support 89-91 includes two legs and a support bar.For example, upper left leg support 89 includes two legs 105-106 andsupport bar 107. Bed frame assembly 80 has a hinge at its middle axis atwhich the lower portion of bedboard frame 92 unfolds from the upperportion. In the embodiment of FIG. 23, the middle axis lies along amiddle plane formed by the two legs 108-109 of the middle leg support91. Hinges on either side of the middle plane pivotally attach thelongitudinal bars 93-96 of the upper and lower portions of the bedboardframe 92 to the middle leg support 91. The hinges are fixedly attachedto the middle leg support 91. The upper and lower leg supports 89-90 arepivotally attached to cross bars 97 and 104, respectively.

After the upper portion of assembly 80 is unfolded from the lowerportion, the upper and lower leg supports 89-90 can be unfolded. Forexample, upper leg support 89 that is pivotally connected to the upperportion of bedboard frame 92 is unfolded and locked into place bydiagonal struts 81-82 and locking mechanisms 85-86. Before upper legsupport 89 is unfolded, the plane of legs 105-106 is parallel to theplane of the upper portion of bedboard frame 92. In addition, thediagonal struts 81-82 are not yet attached to cross bar 98, but areinstead parallel to the plane of legs 105-106. Thus, the diagonal struts81-82 are pivotally attached to support bar 107 and are rotated out ofthe plane of legs 105-106 after upper leg support 89 is unfolded.

FIG. 24 shows the upper portion of bed frame assembly 80 in more detailfrom the underside of bedboard frame 92 after upper leg support 89 hasbeen unfolded and after the diagonal struts 81-82 have been rotated outof the plane of legs 105-106. Struts 81-82 are rotated in oppositedirections to reach slotted brackets 110-111 attached to cross bar 98.For example, diagonal strut 82 is rotated clockwise in the perspectiveof FIG. 24 to reach a slotted bracket 110 that is welded to cross bar98. The locking mechanism 86 is formed between slotted bracket 110 andthe end of diagonal strut 82.

FIG. 25 shows the locking mechanism 86 in more detail from the undersideof bedboard frame 92 before diagonal strut 82 has completely reachedslotted bracket 110. A bolt 112 is fixedly attached to the end ofdiagonal strut 82. A conical washer 113 slides along bolt 112 and isheld on the bolt by a wing nut 114. FIG. 25 also shows a conical washerand wing nut on a bolt at the end of the other diagonal strut 81.Diagonal strut 81 is still in the plane of upper support leg 89 and hasnot yet been rotated so that the end of the strut reaches the slottedbracket 111. Diagonal strut 82 is being rotated such that bolt 112 willpass into a rounded slot 115 in slotted bracket 110. Rounded slot 115has a channel 116 that is only slightly wider than the diameter of bolt112. A round opening 117 at the end of the channel 116 has a diameterlarger than the width of the channel.

FIG. 26 is a schematic diagram from above showing how bolt 112 passesthrough channel 116 and into the round opening 117 of rounded slot 115as diagonal strut 82 is rotated. Wing nut 114 is not shown in FIG. 26.Conical washer 113 is raised above slotted bracket 110 as bolt 112passes through channel 116. Then the coned portion of conical washer 113fits into the round opening 117 once bolt 112 is centered in the roundopening. From the upside-down perspective of FIG. 25, the coned portionfits down into the round opening 117.

FIG. 27 is a cross-sectional schematic diagram of bolt 112 centered inthe round opening 117 of rounded slot 115 before conical washer 113 islowered into the round opening 117. In the right-side-up orientation ofFIG. 23, conical washer 113 rises up into the round opening 117 as wingnut 114 is tightened. In one embodiment, conical washer 113 has a conedportion and a cylindrical portion. The diameter of the cylindricalportion of conical washer 113 is larger than the diameter of the roundopening 117. In another embodiment, conical washer 113 has only theconed portion, and the maximum diameter of the coned portion is largerthan the diameter of the round opening 117. After conical washer 113 islowered into round opening 117 and wing nut 114 is tightened to preventconical washer 113 from rising up, the sides of the coned portion ofconical washer 113 prevent bolt 112 from passing out of the narrowerchannel 116.

FIG. 28 is a perspective schematic view of locking mechanism 86 afterconical washer 113 has been tightened by wing nut 114 into the roundopening 117 of rounded slot 115. The sides of the lower coned portion ofconical washer 113 press against the sides of the round opening 117.FIG. 28 shows that the largest diameter of the coned portion is largerthan the diameter of the round opening 117.

FIG. 29 is a perspective view of locking mechanism 86 in which bolt 112has been rotated into rounded slot 115 but conical washer 113 has notyet been tightened by wing nut 114 all the way down into the roundopening 117.

FIG. 30 is a flowchart illustrating steps 118-12X of a method of settingup mattress support system 66 of FIG. 23. In a first step 118, thecontents are removed from a packing box containing mattress supportsystem 66. In the embodiment of FIG. 23, the packing box includes onlythe components of bed frame assembly 80. Bed frame assembly 80 includesthe upper and lower portions of bedboard frame 92, leg supports 89-91,diagonal struts 81-84 and locking mechanisms 85-88.

In a step 119, the upper portion of bed frame assembly 80 is unfoldedalong a middle axis from the lower portion. The upper portion and thelower portion are pivotally connected at a hinge. In the foldedcondition in the packing box, the leg supports 89-90 are folded into thebottom sides of the upper and lower portions of the bed frame assembly.Each leg support has two legs disposed in a plane, and the two legs areconnected by a support bar.

In a step 120, the leg supports 89-90 are unfolded. For example, upperleg support 89 that is pivotally connected to the upper portion ofbedboard frame 92 is unfolded to an orientation perpendicular to theupper portion. Middle leg support 91 need not be separately unfoldedbecause the middle support is left standing when the upper and lowerportions of bedboard frame 92 are unfolded from one another. After theupper and lower leg supports 89-90 are unfolded, the diagonal struts81-84 can be conveniently locked into place using the locking mechanisms85-88.

In a step 121, the diagonal struts 81-82 are rotated out of the planesof the leg supports 89-90. For example, diagonal strut 81 that ispivotally attached to support bar 107 of upper leg support 89 is rotatedout of the plane of the leg support, and diagonal strut 82 that ispivotally attached to support bar 107 is also rotated out of the planeof upper leg support 89. Bolt 112 is fixedly attached to an end ofdiagonal strut 82 opposite support bar 107, and conical washer 113passes over bolt 112 and is held on bolt 112 by wing nut 114.

In a step 122, the bolts at the ends of the diagonal struts are rotatedinto rounded slots in slotted brackets that are attached to cross bars.For example, bolt 112 is inserted through channel 116 and into roundopening 117 of rounded slot 115 in slotted bracket 110 by rotatingdiagonal strut 82. Slotted bracket 110 is attached to cross bar 98 ofbedboard frame 92.

In a step 123, the wing nuts are tightened so as to press the conedportions of the conical washers into the round openings in the slottedbrackets, which prevents the bolts from slipping out of the roundedslots and thereby locks the unfolded leg supports in place. For example,wing nut 114 is tightened so as to press conical washer 113 down intoround opening 117 such that the sides of the lower coned portion ofconical washer 113 press against the sides of the round opening 117.

In a step 124, the unfolded bed frame assembly 80 is stood on theunfolded and locked leg supports 89-91. For example, the unfolded bedframe assembly 80 is stood on the leg supports 89-91, including theunfolded and locked leg support 89.

In a step 125, a headboard attachment is attached to upper leg support89. Because leg support 89 is locked into place by diagonal struts 81-82and locking mechanisms 85-86, the leg support is stable enough to holdthe headboard attachment and the headboard.

In a step 126, a mattress is placed on top of the assembled bed frameassembly 80.

FIG. 31 is a perspective view of two hinged brackets for headboardsupport of the bed frame assembly 80 of FIG. 23. The view of FIG. 31 isfrom the upper side of the bed frame assembly 80. The upper side of thebedboard frame 92 includes an upper side edge bar 128 and the twolongitudinal bars 93 and 94. The longitudinal bars 93 and 94 are alsoreferred to as outer side edge bars. A hinged bracket (right side) 129is secured to the longitudinal bar 94 and the upper side edge bar 128. Ahinged bracket (left side) 130 is secured to the longitudinal bar 93 andthe upper side edge bar 128. Both hinged brackets 129 and 130 have thesame design and are manufactured in the same way. In the embodimentshown in FIG. 31, the hinged brackets 129 and 130 are secured to thebedframe assembly 80 using screws.

FIG. 32 shows the upper-left portion of bed frame assembly 80 in moredetail after the hinged bracket (left side) 130 has been unfolded andsecured to the bedboard frame 92. The hinged bracket 130 includes afirst planar metal plate portion 131, a second planar metal plateportion 142, a first hinge 153 and a second hinge 157. The first planarmetal plate portion 131 includes a first lip 134, a first slot 135, asecond slot 136, and a third slot 137. The first lip 134 rests on top ofthe upper side edge bar 128. The first planar metal plate portion isscrewed into an outer edge of upper side edge bar 128 through the thirdslot 137. The first planar metal plate portion 131 hangs down from theupper side edge bar 128. In one embodiment, the headboard of the bedframe assembly 80 is attached to the hinged bracket 130 below the upperside edge bar 128.

The second planar metal plate portion 142 includes a second lip 145, afourth slot 146, a fifth slot 147, and a sixth slot 148. The second lip145 rests on top of the longitudinal bar 93. The second planar metalplate portion 142 is screwed into an outer edge of the longitudinal bar93 through the sixth slot 148. The first planar metal plate portion 131is pivotally attached to the second planar metal plate portion 142 atthe second hinge 157.

Similarly, the hinged bracket (right side) 129 mirrors the components ofthe hinged bracket (left side) 130. For example, the hinged bracket 129has a first metal plate portion that includes a first lip, a first slot,a second slot, and a third slot. In this example, the first lip rests ontop of the longitudinal bar 94, and the first planar metal portion isscrewed into an outer edge of the longitudinal bar 94. Furthermore, inthis example, the hinged bracket 129 has a second metal plate portionthat includes a second lip, a fourth slot, a fifth slot, and a sixthslot, wherein the second lip rests on top of the upper side edge bar 128and the second planar metal portion is screwed into an outer edge of theupper side edge bar 128 (see FIG. 31). In the embodiment shown in FIG.32, the first planar metal plate portion 131 is oriented perpendicularto the second planar metal plate portion 142, and the hinged bracket 130is supported by the bed frame assembly 80. The hinged bracket 129 isalso supported by the bed frame assembly 80 in a similar fashion to thatof the hinged bracket 130.

Furthermore, the hinged brackets 129 and 130 are adapted to hold aheadboard of a bed. For example, the hinged bracket 130, shown in FIG.32, includes the first slot 135 and the second slot 136, wherein eachslot is capable of receiving a tongue of the headboard. In anotherexample, the tongue of the headboard slides into the fourth slot or thefifth slot of the hinged bracket 129.

FIG. 33 is a perspective schematic view of the hinged bracket (leftside) 130. The view of FIG. 33 is the reverse view of FIG. 32 withoutthe bedframe assembly 80. The hinged bracket 130 includes the firstplanar metal plate portion 131, the second planar metal plate portion142, the first hinge 153, and the second hinge 157.

The first planar metal plate portion 131 includes a first upper edge132, a first descending edge 133, the first lip 134, the first slot 135,the second slot 136, the third slot 137, a seventh slot 158, an eighthslot 159, and a first opening 162. The first planar metal plate portion131 also includes a first curved section 140 and a third curved section141, as shown in FIG. 34. Each curved section is made from a rolledtongue that extends from the first planar metal plate portion 131opposite the first descending edge 133. The first curved section 140 andthe third curved section 141 together form a first portion of the firsthinge 139, as shown in FIG. 33.

The second planar metal plate portion 142 includes a second upper edge143, a second descending edge 144, the second lip 145, the fourth slot146, the fifth slot 147, the sixth slot 148, a ninth slot 160, a tenthslot 161, a second opening 163. The second planar metal plate portion142 also includes a second curved section 151 and a fourth curvedsection 152 (see FIG. 34). The second curved section 151 and the fourthcurved section 152 together form a second portion of the first hinge 150as shown in FIG. 33.

The first hinge 153 includes the first portion 139 of the first hinge,the second portion 150 of the first hinge, a pin 154, and a nut 155. Thepin 154 slides through the first curved section 140, the second curvedsection 151, the third curved section 141, and the fourth curved section152. The lower end of the pin 154 is secured using the nut 155. Thefirst portion 139 of the hinge adjoins the second portion 150 of thehinge at a hinged edge of the hinged bracket 130. The first planar metalplate portion 131 and the second planar metal plate portion 142 areadjoined at a hinge axis 156. The first planar metal plate portion 131and second planar metal plate portion 132 rotate axially around thehinge axis 156. The first planar metal plate portion 131 has a lengthalong its hinged edge of less than fourteen inches.

The second hinge 157 comprises a first portion of the second hinge 164,a second portion of the second hinge 165, a pin 179 and a nut 180. Thefirst portion of the second hinge 164 includes a fifth curved section166 and a seventh curved section 167, which are part of the first planarmetal plate portion 131 (see FIG. 34). The second portion of the secondhinge 165 includes a sixth curved section 168 and an eighth curvedsection 169, which are part of the second planar metal plate portion 142(see FIG. 34). The pin 179 slides through both the first portion 164 andthe second portion 165 of the second hinge 157 and is secured using thenut 180. The first hinge 153 and the second hinge 157 are disposed alongthe hinged axis 156.

In one embodiment, the first planar metal plate portion 131 has a tophalf and a bottom half. The top half of the first planar metal plateportion 131 includes the first upper edge 132, the first lip 134, thethird slot 137, the first portion of the first hinge 139, and the firstopening 162. The bottom half of the first planar metal plate portion 131includes the first slot 135, the eighth slot 159, and the first portionof the second hinge 164. The first lip 134 aligns the first upper edge132 of the first planar metal plate portion 131 with the upper side edgebar 128 (see FIG. 32). The first upper edge 132 of the first planarmetal plate portion 131 is perpendicular to the first portion of thefirst hinge 139. The bottom half of the first planar metal plate portion131 is opposite the first upper edge 132 of the first planar metal plateportion 131. The first descending edge 133 is opposite the first portionof the first hinge 139 but is not parallel to the first portion of thefirst hinge 139. The hinged bracket 130 is designed such that no part ofthe bed frame assembly 80 contacts the bottom half of the first planarmetal plate portion 131 (see FIG. 32).

Furthermore, in this embodiment, the second planar metal plate portion142 has a top half and a bottom half. The top half of the second planarmetal plate portion 142 includes the second upper edge 143, the secondlip 145, the sixth slot 148, the second portion of the first hinge 150,and the second opening 163. The bottom half of the second planar metalplate portion 142 includes the fourth slot 146, the tenth slot 161, andthe second portion 165 of the second hinge 157. The second lip 145aligns the second upper edge 143 of the second planar metal plateportion 142 with the longitudinal bar 93 (see FIG. 32). The second upperedge 143 of the second planar metal plate portion 142 is perpendicularto the second portion of the first hinge 150. The bottom half of thesecond planar metal plate portion 142 is opposite the second upper edge143 of the second planar metal plate portion 142. The second descendingedge 144 is opposite the second portion of the first hinge 150 but isnot parallel to the second portion of the first hinge 150. The hingedbracket 130 is designed such that no part of the bed frame assembly 80contacts the bottom half of the second planar metal plate portion 142(see FIG. 32).

FIG. 34 is a perspective schematic view of the hinged bracket (leftside) 130 of FIG. 33 in a flat open orientation in which the firstplanar metal portion 131 is on the same plane as the second planar metalportion 142. FIG. 34 shows that the first planar metal plate portion 131includes the first curved section 140, the third curved section 141, thefifth curved section 166, and the seventh curved section 167. The secondplanar metal portion 142 includes the second curved section 151, thefourth curved section 152, the sixth curved section 168, and the eightcurved section 169.

The second curved section 151 of the second planar metal portion 142 isadjacent to both the first curved section 140 and the third curvedsection 141 of the first planar metal portion 131. The sixth curvedsection 168 of the second planar metal portion 142 is adjacent to boththe fifth curved section 166 and the seventh curved section 167 of thefirst planar metal portion 141.

FIG. 35 shows how the first and second planar metal plate portion of thehinged bracket 130 are pivotally adjoined around a hinge axis 156. Thefirst planar metal plate portion 131 includes a first metal tongue 171,a third metal tongue 172, a fifth metal tongue 175, and a seventh metaltongue 176 that are opposite the first descending edge 133. The secondplanar metal plate portion 142 includes a second metal tongue 173, afourth metal tongue 174, a sixth metal tongue 177, and an eighth metaltongue 178 that are opposite the second descending edge 144.

In a next manufacturing step, the first metal tongue 171, the thirdmetal tongue 172, the fifth metal tongue 175, and the seventh metaltongue 176 are shaped (rolled) to form the first curved section 140, thethird curved section 141, the fifth curved section 166, and the seventhcurved section 167, respectively. The second metal tongue 173, thefourth metal tongue 174, the sixth metal tongue 177, and the eighthmetal tongue 178 are rolled to form the second curved section 151, thefourth curved section 152, the sixth curved section 168, and the eighthcurved section 169, respectively.

The first portion 139 of the first hinge 153 includes the first curvedsection 140 and the third curved section 141 (see FIGS. 33-34). Thesecond portion 150 of the first hinge 153 includes the second curvedsection 151 and the fourth curved section 152 (see FIGS. 33-34). Thefirst portion 164 of the second hinge 157 includes the fifth curvedsection 166 and the seventh curved section 167 (see FIGS. 33-34). Thesecond portion 165 of the second hinge 157 includes the sixth curvedsection 168 and the eighth curved section 169 (see FIGS. 33-34).

In a next manufacturing step, the pin 154 is slid through the first andsecond portions of the first hinge and is secured by the nut 155,creating the first hinge 153. The pin 179 is inserted through the firstand second portions of the second hinge and is secured by the nut 180,creating the second hinge 157. The first hinge 153 and second hinge 157are aligned with the hinge axis 156. The first planar metal plateportion 131 and the second planar metal plate portion 142 rotatepivotally about the hinge axis 156. In a packaging step, the firstplanar metal plate portion 131 and the second planar metal plate portion142 are rotated open such that they are oriented in the same plane.Alternatively, the first planar metal plate portion 131 is folded overthe second planar metal plate portion 142 such that the planes of bothplates are parallel to each other. Either packaging step reduces thewidth of the bracket 130 in the packing box compared to a bracket whoseplanar plates are fixed at a right angle to one another. Thus, byfolding the hinged bracket 130 closed or completely open, the volumeoccupied by the bracket in the packing box is reduced. FIG. 35 shows thefirst planar metal plate portion 131 folded over the second planar metalplate portion 142 as the hinged bracket 130 would be shipped in apacking box.

The hinged bracket (right side) 129 is designed in the same way as thehinged bracket (left side) 130. The only difference between bracket 129and bracket 130 is how each bracket is attached to the bedboard frame 92(see FIG. 31).

Although certain specific embodiments are described above forinstructional purposes, the teachings of this patent document havegeneral applicability and are not limited to the specific embodimentsdescribed above. For example, in another embodiment, the hinged brackets129 and 130 each have more or less than two hinges. In yet anotherembodiment, the first planar metal portion 131 and the second planarmetal portion 142 each have more or less than five slots. Accordingly,various modifications, adaptations, and combinations of various featuresof the described embodiments can be practiced without departing from thescope of the invention as set forth in the claims.

1-20. (canceled)
 21. An apparatus comprising: a first planar metal plateportion that has a first slot and a first portion of a hinge; a secondplanar metal plate portion having a second portion of the hinge, whereinthe first portion of the hinge adjoins the second portion of the hingeat a hinged edge, and wherein the first planar metal portion ispivotally attached to the second planar metal portion at the hingededge; a first lip that meets the first planar metal plate portion at anupper edge of the first planar metal plate portion, wherein the upperedge of the first planar metal plate portion is perpendicular to thefirst portion of the hinge, and wherein a bottom half of the firstplanar metal plate portion is opposite the upper edge of the firstplanar metal plate portion; and a second lip that meets the secondplanar metal plate portion at an upper edge of the second planar metalplate portion, wherein the upper edge of the second planar metal plateportion is perpendicular to the second portion of the hinge, wherein thefirst planar metal plate portion has a first descending edge that isopposite the first portion of the hinge but that is not parallel to thefirst portion of the hinge, wherein the second planar metal plateportion has a second descending edge that is opposite the second portionof the hinge but is not parallel to the second portion of the hinge,wherein the first slot is disposed in the bottom half of the firstplanar metal plate portion and is oriented parallel to the upper edge ofthe first planar metal plate portion, and wherein the apparatus isadapted to be supported by a bed frame assembly such that no part of thebed frame assembly contacts the bottom half of the first planar metalplate portion.
 22. The apparatus of claim 21, wherein the first portionof the hinge includes a first curved section and a third curved section,wherein the second portion of the hinge includes a second curved sectionand a fourth curved section, and wherein the second curved section isdisposed between the first curved section and the third curved section.23. The apparatus of claim 22, wherein a pin passes through the first,second, third and fourth curved sections.
 24. The apparatus of claim 21,wherein the bed frame assembly includes an upper side edge bar and anouter side edge bar, wherein the first lip rests on the upper side edgebar, wherein the second lip rests on the outer side edge bar, andwherein the first planar metal plate portion hangs down from the upperside edge bar.
 25. The apparatus of claim 21, wherein the bed frameassembly includes an upper side edge bar and an outer side edge bar,wherein the first planar metal plate portion is screwed into and hangsdown from the upper side edge bar, and wherein the second planar metalplate portion is screwed into and hangs down from the outer side edgebar.
 26. The apparatus of claim 21, further comprising: a headboard of abed, wherein the headboard is attached to the first planar metal plateportion.
 27. The apparatus of claim 26, wherein the headboard includes atongue that slips into the first slot of the first planar metal plateportion.
 28. The apparatus of claim 21, wherein the first planar metalplate portion includes a second slot, and wherein the second slot isoriented parallel to the first slot.
 29. The apparatus of claim 21,wherein the first descending edge is straight and descends diagonallydown from the upper edge of the first planar metal plate portion. 30.The apparatus of claim 21, wherein the first planar metal plate portionhas a length along the hinged edge of less than fourteen inches.
 31. Theapparatus of claim 21, wherein the first lip is a means for hanging theapparatus from a side edge bar of a folding bed frame.
 32. An apparatuscomprising: a first planar metal plate portion that has a slot, a firstrolled tongue and a second rolled tongue; a second planar metal plateportion that has a third rolled tongue and a fourth rolled tongue; a pinthat passes through the first, second, third and fourth rolled tonguesat a hinge axis, wherein the first planar metal plate portion ispivotally attached to the second planar metal plate portion at the hingeaxis; a first lip that meets the first planar metal plate portion at anupper edge of the first planar metal plate portion, wherein the upperedge of the first planar metal plate portion is perpendicular to thefirst portion of the hinge, and wherein a bottom half of the firstplanar metal plate portion is opposite the upper edge of the firstplanar metal plate portion; and a second lip that meets the secondplanar metal plate portion at an upper edge of the second planar metalplate portion, wherein the upper edge of the second planar metal plateportion is perpendicular to the second portion of the hinge, wherein thefirst planar metal plate portion has a first descending edge that isopposite the first portion of the hinge but that is not parallel to thefirst portion of the hinge, wherein the second planar metal plateportion has a second descending edge that is opposite the second portionof the hinge but is not parallel to the second portion of the hinge,wherein the slot is disposed in the bottom half of the first planarmetal plate portion and is oriented parallel to the upper edge of thefirst planar metal plate portion, and wherein the apparatus is adaptedto be supported by a bed frame assembly such that no part of the bedframe assembly contacts the bottom half of the first planar metal plateportion.
 33. The apparatus of claim 32, wherein the first planar metalplate portion is oriented perpendicular to the second planar metal plateportion when the apparatus is supported by the bed frame assembly. 34.The apparatus of claim 32, further comprising: a cardboard packing box,wherein the first planar metal plate portion is folded over the secondplanar metal plate portion in the cardboard packing box such that thefirst planar metal plate portion and the second planar metal plateportion are oriented parallel to each other.
 35. The apparatus of claim32, further comprising: a nut, wherein the pin is threaded, and whereinthe nut is screwed onto the pin.
 36. An apparatus comprising: a bedframe assembly with a first hinge at its middle axis at which the bedframe assembly folds, wherein the bed frame assembly has an upper sideedge bar and an outer side edge bar; and an edge attachment thatattaches both to the upper side edge bar and to the outer side edge bar,wherein the edge attachment hangs down from the upper side edge bar andfrom the outer side edge bar, wherein a first planar portion of the edgeattachment is pivotally attached to a second planar portion of the edgeattachment at a second hinge, and wherein the edge attachment is adaptedto hold a headboard.
 37. The apparatus of claim 36, wherein the firstplanar portion is oriented perpendicular to the second planar portionwhen the edge attachment is attached to both the upper side edge bar andto the outer side edge bar.
 38. The apparatus of claim 36, wherein theedge attachment has a slot, and wherein a tongue on the headboard fitsinto the slot in the edge attachment.
 39. The apparatus of claim 36,further comprising: the headboard, wherein the headboard is attached tothe edge attachment at a location below the upper side edge bar.
 40. Theapparatus of claim 36, further comprising: the headboard, wherein theheadboard has a tongue that slips into a slot in the first planarportion.